Radiation polymerizable epoxy composition

ABSTRACT

A radiation curable epoxy composition prepared by admixing an epoxy compound having the formula   IN WHICH A is   AND N HAS AN AVERAGE VALUE OF 0-13 AND A COMPOUND HAVING THE FORMULA   in which R1, R3, and R4 are lower alkyl groups, and R2 is an alkylene group having 2-8 carbon atoms.

United States Patent Marans et al.

[ Dec. 30, 1975 [54] RADIATION POLYMERIZABLE EPOXY COMPOSITION Inventors: Nelson S. Marans; Alfred Gluecksmann, both of Silver Spring, Md.

W. R. Grace & Co., New York, NY.

Filed: Aug. 17, 1973 App]. No.: 389,316

Assignee:

US. Cl 260/837 R; 204/159.15; 260/836; 427/53; 427/54 Int. Cl. C08F 2/46; C08F 2/50; C08L 63/02; C08L 63/10 Field of Search 260/836, 837 R; 204/159.15

[56] References Cited UNITED STATES PATENTS 3,455,858 7/1969 Taft 260/836 FOREIGN PATENTS OR APPLICATIONS 106,179 1/1963 Czechoslovakia 260/836 OTHER PUBLICATIONS Speitel, Rene, Chemical Abstracts, Vol. 72, (1970), p. 72, Article No. 101928A. Meincke et al., Chemical Abstracts, Vol. 77, (1972), p. 50, Article No. 49472.].

Primary Examiner-John C. Bleutge Assistant Examiner-Thurman Kennis Page Attorney, Agent, or FirmElton Fisher [57] ABSTRACT A radiation curable epoxy composition prepared by admixing an epoxy compound having the formula in which A is I H1 OH and n has an average value of 0-13 and a compound having the formula RADIATION POLYMERIZABLE EPOXY COMPOSITION BACKGROUND OF THE INVENTION in which A is and n has an average value of -1 3 and -60 parts of an ethylenically unsaturated compound having the formula in which A is and n has an average value of 0-l3, and 5-60 parts of a compound having the formula in which R is hydrogen or a lower alkyl group, R and R are lower alkyl groups, and R is an alkylene group having 2-8 carbon atoms.

R can be the same as or different from R and/or R Epoxy compounds of the type recited above are well known to those skilled in the art and are described in:

1. Lee et a1, Epoxy Resins, Their Application and Technology", McGraw-Hill Book Company, lnc., New York, New York 1957.

2. Lenz, Organic Chemistry of Synthetic High Polymers, John Wiley & Sons lnc., New York, New York 1968.

3. The Kirk-Othmer Encyclopedia of Chemical Technology, John Wiley & Sons, lnc., New York, New York Vol. 8, 1965.

US. Pat. No. 3,674,545 (Strolle, ll7/93.31)teaches the use of high energy ionizing radiation to cure a rather complex mixture having an epoxy phosphate syrup as one of its components.

SUMMARY OF THE INVENTION In summary, this invention is directed to a radiation curable composition consisting essentially of an intimate mixture of 40-95 parts of an epoxy compound having the formula in which R is hydrogen or a lower alkyl group, R and R are lower alkyl groups, and R is an alkylene group having 2-8 carbon atoms.

DESCRIPTION OF PREFERRED EMBODIMENTS In preferred embodiments of the invention recited in the above Summary:

I. n is 0-6.

2. There are present 40-95 parts of the epoxy compound and 5-60 parts of the ethylenically unsaturated compound.

3. R R and R are methyl groups and R is CH CH 4. There is present 0.01-5 parts (more preferably 0.05l.5 parts) of a photocuring rate accelerator per 100 parts of the epoxy compound. Preferred photocuring rate accelerators include benzophenone, dibenzosuberone, or acetophonone.

a. Where the photocuring rate accelerator is present the composition can be cured by a process comprising irradiating a film (or coating) of the composition with actinic light (actinic radiation, preferably having a wave length of 2000-4000 A at a rate to provide 0.0001-20 watts per square centimeter of film surface for a period of about 0.001-120 minutes (preferably 0.01- minutes.)

5. Where a photocuring rate accelerator is present it is preferred to have present parts of the epoxy compound and 5-l70 parts of the ethylenically unsaturated compound.

In another preferred embodiment (Embodiment A) this invention is directed to; (a) a process for curing (polymerizing) the composition of the above Summary comprising irradiating said composition with 3 0.1-5 Mrads (more preferably 0.5-2.5 Mrads) of high energy ionizing radiation; and (b) to the polymer formed by said process.

In another preferred embodiment (Embodiment B") this invention is directed to; (a) a process for curing (polymerizing a mixture consisting essentially of the composition of the above Summary in which there is present (and intimately admixed therein) 0.0l-5 parts of a photocuring rate accelerator per 100 parts of the epoxy compound of said Summary, said process comprising irradiating a film of said mixture with actinic light preferably having a wave length of 2000-4000A at a rate to provide 0.000lwatts per square centimeter of film surface; and (b) the polymer formed by said process.

DETAILED DESCRIPTION OF THE INVENTION We have made the surprising discovery that compositions consisting essentially of an intimate mixture of an epoxy compound of the type recited 'in the above Summary and an ethylenically unsaturated compound having the formula in which R, is hydrogen or a lower alkyl group, and R and R, are lower alkyl groups and R is an alkylene group having 2-8 carbon atoms is cured (polymerized) where subjected to high energy ionizing radiation including X-rays, gamma rays, an electron beam, a neutron beam, or a proton beam. The radiation dosage required to produce a good cure being about 0.l-5.0 (preferably about 0.52.5 Mrads.

This result (the curing of our composition) is surprising because a similar dosage of radiation failed. to cure the epoxy component of our composition where said epoxy component was irradiated in the absence of the ethylenically unsaturated compound.

This result (the curing of our composition) is even more surprising because a similar dosage of radiation failed to cure our ethylenically unsaturated compound in the absence of the epoxy compound.

Our composition was stable and did not polymerize where stored for several weeks in the absence of significant radiation.

We have also found that, where a photocuring rate accelerator (or a mixture of such accelerators) is present in our composition (an intimate mixture of the epoxy compound and the ethylenically unsaturated compound, both being described in the above Summary) said composition is readily cured by irradiation with actinic light including ultraviolet light having a wave length of about 2000-4000 A.

Preferred photocuring rate accelerators include but are not limited to benzophenone, acetophenone, acenaphthenequinone, o-methoxybenzophenone, thioxan-. then-9-one, xanthen-9-one, 7-one, dibenzosuberone, l-naphthaldehyde, 4,4-bis(- dimethylamino) benzophenone, fluoren-9-one, l-indanone, 2-tert-butylanthraquinone, valerophenone, hexanophenone, 8-phenylbutyrophenone, p-morpholinoproprophenone 4-morpholinobenzophenone, 4'-morpholinodeoxybenzoin, p-diacetylbenzene, 4-aminobenzophenone, 4'-methoxyacetophenone, benzaldehyde,

7H-benz[de]anthracenwhich cured our above-mentioned compositions (the compositions of Embodiments 4 and 5 of the Preferred Embodiments, supra).

Samples of our composition containing 0.01-5 parts of the above named photocuring rate accelerators per I00 parts of epoxy compound were stable and did not polymerize where stored for several weeks in the absence of significant amounts of radiation including the absence of actinic light.

Epoxy compounds used in preparing cured epoxy resins are frequently admixed with additives such as diluents, fillers, plasticizers, and flexibilizers that are well known to those skilled in the art and are described in some detail in Chapters 6 and 7 of the above-mentioned Lee et al reference. We have found that moderate amounts (e.g., up to 5-10% or more) of such additives can be presentinthe composition of our invention without adversely effecting the quality of the cured resin obtained where the composition of our invention is cured by high energy ionizing radiation or by radiation with actinic light.

Amino compounds having'the formula CH,=(ICOOR,-N

wherein R,, R R and R, are as defined in the above Summary which were found to be especially useful in the composition and process of our invention include but are not limited to; dimethylaminoethyl methacrylate; diethylaminoethyl methacrylate; dimethylaminopropylv methacrylate; dimethylaminobutyl methacrylate; dimethylaminoethyl acrylate; diethylaminoethyl acrylate; dimethylaminopropyl acrylate; dimethylaminobutyl acrylate; those compounds having said formula in which; R, is C 14 R is CH CH and (l) R, and R are both; (a) CH, (b) C ll (c) CH CH Ch (d) CH,CH CH' CH,,; and (e) CH CH(CH those compounds having said formula in which; R, is CH;,; R is cruel-1,; R is CH and (II) R,.is (a) C H (b) CH CH CH (c) CH CH CH,CH and (d) CH CH(CH those compounds having said formula in which R, is CH CH CH CH R is CH CH CH CH Cl-l and (lll) R and R are both (a) CH C H (b) CH CH CH (c) CH CH CH CH (d) CH CH(CH and (e) CH Cl-l Cl-l cH CH and those'compounds having said formula in which R, is any lower alkyl group; R is'any alkylene group having 2-8 carbon atoms; R, is any lower alkyl group; and R, is any lower alkyl group.

The instant invention will be better understoodby referring to the following specific but nonlimiting ex,- amples. It is understood that said invention is not limited by said examples which are offered merely as illustrations; it is also understood that modifications can be made without departingfrom the spirit and scope of the invention.

EXAMPLE 1 EXAMPLE 2 The general procedure of Example 1 was repeated. However, in this instance 90 parts of Epon 828 was admixed with parts of dimethylaminoethyl methacrylate. The resulting mixture was designated Composition 2.

A coating of Composition 2, where applied to a glass plate and irradiated with an electron beam (1.25 Mrads) formed a hard coating which adhered firmly to the glass plate.

EXAMPLE 3 The general procedure of Example I was repeated. However, in this instance 95 parts of Epon 828 was admixed with 5 parts of dimethylaminoethyl methacrylate to form a mixture which was designated Composition 3".

A thin coating of Composition 3 was applied to a glass plate and irradiated as in Example 1, but using a dosage of 1.5 Mrads. The coating on the glass plate cured to form a hard film which adhered firmly to the glass plate.

EXAMPLE 4 The general procedure of Example I was repeated. However, in this instance the Epon 828 was replaced with Epon 1001 a commercially available epoxy compound having a higher average molecular weight than Epon 828. Lee et al. state (page that the average molecular weight of Epon 828 is 350-400 and that the average molecular weight of Epon 1001 is 900-1000. 50 parts of Epon 1001 was admixed with 50 parts of dimethylaminoethyl methacrylate to form a mixture which was designated Composition 4.

A film of Composition 4 was applied to a glass plate which was then irradiated as in Example I using a dosage of 1.25 Mrads. The film cured to form a hard coating firmly adhering to the glass plate.

EXAMPLE 5 A film of Epon 828 was applied to a glass plate and irradiated as in Example I. The film did not cure at a radiation dosage of 1.25 Mrads. Neither did said film cure when the dosage was increased to 8 Mrads.

EXAMPLE 6 A film of dimethylaminoethyl methacrylate was applied to a glass plate and irradiated as in Example 1.

The film did not cure at a radiation dosage of 1.25 Mrads. Neither did said film cure when the dosage was increased to 8 Mrads.

EXAMPLE 7 g A composition designated Composition 7 was prepared by admixing benzophenone and a portion of the above-described Composition 1. A total of 1% benzophenone, based on the weight of the resulting composition 7 was admixed with said composition 1.

EXAMPLE 8 A series of runs was made repeating the general procedure of Example 7. However, in said runs, Composition 1 was replaced with Compositions 2-4 (as indicated in Table I) and the resulting benzophenone-containing compositions, each of which contained 1% benzophenone, were designated as indicated in said table.

TABLE I Preparation of Benzophenone-Containing Compositions Starting Run No. Composition Designation of Resulting Comp.

1 Composition 2 2 Composition 3 3 Composition 4 Composition 8-A Composition 8-B Composition 8-C" EXAMPLE 9 A film of Composition 7 was applied to a glass plate which was then irradiated for 6 minutes with actinic light from a 275 watt Westinghouse Sunlamp positioned to provide a radiation dosage of 4000 microwatts per square centimeter of the films surface as measured with a short wavelength ultraviolet meter. The film cured to form a hard smooth coating firmly adhering to the glass plate.

EXAMPLE l0 A series of runs was made using the general procedure of Example 9 but modified by replacing Composition 7 of Example 9, with Compositions 8-A, 8-B, and 8-C as shown in Table II. Irradiation time, for each run is also shown in Table II.

TABLE II Irradiation of Compositions with Actinic Light Run No. Composition Irradiated Irradiation Time. Minutes I S-A 40 2 8-B 40 3 8-C 6 In each instance the film of irradiated composition cured to form a hard smooth film firmly adhering to the glass plates.

EXAMPLE I l EXAMPLE l2 As used herein the term percent means parts per hundred, and the term parts means parts by The general procedure of Example 1 l was repeated. weight. However, in this instance the Epon 828 was replaced As used herein the term lower alkyl group means with dimethylaminoethyl methacrylate, and the resultan alkyl group having 1 to about 7 carbon atoms. ing mixture of dimethylaminoethyl methacrylate and As used herein the term Mrad means megarad. benzophenone was designated Composition 12". We claim:

A film of Composition 12 on a glass plate did not 1. A radiation curable composition consisting of cure on being irradiated for 6, l0, and 60 minutes. 4095 parts of an epoxy compound having the formula The compositions of this invention are useful for in which A is forming hard protective films on surfaces including wooden, metal, and glass surfaces. Such surfaces in- I clude the surfaces of furniture walls, countertops, 9 sinks, floors, roofs, artistic designs, and the like. Other 0 c O--CH --CH-CH uses of said compositions will, because of our diselo- 1 sure be readily apparent to those skilled in the art.

Preferred film thickness (thickness of cured film) are 0.05-20 (or 0. l5) mils; however, the film thickness is not critical and excellent results have been obtained and has an average Value 0f0-13 and Parts of an with thicker and thinner films. It is well known to those ethylenically unsaturated Compound having the skilled in the art that the presence of fillers which are mula opaque to actinic light (actinic radiation) can substantially decrease the penetration of actinic light into (or R through) a film, coating, or layer of a photocurable CH =CCOO-R N composition and hence decrease the thickness of such 2 2 composition which can be cured where the composi- 1 4 tion is exposed to a specific or predetermined dosage of actinic radiation. Such fillers are known to those skilled in which Rl iS hydrogen or a lower aikyi group, R2 is an m the alkylene group having 2-8 carbon atoms, and R and R It is also known to those skilled in the art that high are lower alk l groups.

energy ionizing radiation has certain depths of penetra- 2 The composition of ciaim 1 in Which n iS tion in any given system depending on the energy and type of radiation. 

1. A RADIATION CURABLE COMPOSITION CONSISTING OF 40-95 PARTS OF AN EPOXY COMPOUND HAVING THE FORMULA
 2. The composition of claim 1 in which n is 0-6. 